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e-Manufacturing: Fundamentals, Applications and Potentials

Professor Kai Cheng Advanced Manufacturing & Enterprise Engineering (AMEE) Group

School of Engineering & Design, Brunel UniversityUxbridge UB8 3PH, UK

Tel: 08195-267255 Fax: 08195-269703 email: kai.cheng@brunel.ac.uk

Dr Richard BatemanCERAM Research LtdQueens Road, Penkull

Stoke-on-Trent, UK. ST4 7LQTel: (0) 1782 764349 email: richard.bateman@ceram.com

• Background

- Why e-manufacturing?

- What is e-manufacturing?

• e-Manufacturing fundamentals

- Internet enabled technologies

- Advanced technologies for e-manufacturing

- Internet and manufacturing knowledge management

- Computing infrastructure for e-manufacturing

• e-Manufacturing applications and potentials

- Collaborative design and product development

- Mass customization and customer oriented e-manufacturing

- Remote control and condition monitoring

- Virtual manufacturing and systems

- e-Supply chain management

- e-Enterprise and global manufacturing

• Conclusions and the future ‘standing’

Outline of the presentatione-Science

The characteristics of e-manufacturing emphases the new philosophy through which manufacturing will be operated in integration with Internet technology. e-manufacturing philosophy results from that the way people work is being changed by the Internet, for instance:

• Digitisation• Globalisation• Mobility• Collaborative work• Immediacy

Why e-Manufacturing?e-Science

Manufacturing globalization - e-Manufacturing (1)

DesignManufacturing

Sale

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Distributed manufacturing - e-Manufacturing (2)e-Science

Development of manufacturing technology

Mass Production

Flexible Manufacturing

Computer IntegratedManufacturing

Lean Manufacturing

Just-In-Time

Concurrent Engineering

Agile Manufacturing

Production line& automation

Group technology& CNC, robotics

CAD/CAM, DNC& robotics

TQM &engineering tools

TQM, MRP II &engineering tools

CAX &engineering tools

e-ManufacturingDigital enterprise

ManufacturingTechnology

Towards 21st Century

• High precision• Automation

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Transformation by e-Manufacturing

• Mass production

• Long pipeline

• Sale from stock

• Sequential processes

• Cost of inventory

• Wait in line

• Mass customisation

• Shrinking supply chain

• Make to order

• Simultaneous processes

• Capital working

• First available slot

- Manufacturing 2020 Foresight Report

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UK e-Science research program(2001 onward)

What is meant by e-Science? In the future, e-Science will refer to the large scale science that will increasingly be carried out through distributed global collaboration enabled by the Internet. Typically, a feature of such collaborative scientific enterprises is that they will require access to very large data collections, very large scale computing resources and high performance visualisation back to the individual user scientists.

The Core Program has been structured around 6 key elements:

• A national e-Science centre linked to a network of regional grid centres

• Generic grid middleware and demonstrator projects

• Grid ‘IRC’ research projects

• Support for e-Science testbeds

• Participation in international grid projects and activities

• Establishment of a grid network team

- http://www.rcuk.ac.uk/escience/

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EU 6th Framework - IST program(2004 onward)

Applied IST research addressing major societal and economic challenges:

• Towards a global dependability and security framework

• Networked business and government

• e-Safety for road and air transport

• e-Health

• Technology-enhanced learning and access to cultural heritage

• Applications and services for the mobile user and worker

• Cross media content for leisure and entertainment

• Grid-based systems for solving complex problems

• Improving risk management

• e-Inclusion

• Products and services engineering 2010

- http://www.cordis.lu/ist/activities/activities.htm

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e-manufacturing covers a range of online manufacturing activities for products and services, including product design, production control and conditions monitoring, supply chain management, maintenance and sale services, etc., through the Internet/Intranet/Extranet and grid computing infrastructure.

What is e-Manufacturing? - (1)e-Science

e-manufacturing is the complete electronic (computer systems and networks) integration of all factory components. Users range from operators to technicians to engineers to managers.

- UK Industrial White Paper (2002)

What is e-Manufacturing? - (2)e-Science

• Internet Enabled Technologies- HTML- Java programming- XML- Client/server architecture- Java database connectivity

• Advanced Technologies for e-Manufacturing- Agent technology- Multi-agent systems- Data mining and knowledge discovery- Grid computing

• Internet and Manufacturing Knowledge Management- Internet characteristics - Design agility and the Internet - Manufacturing responsiveness and the Internet - CBR and web-based computational intelligence

• Computing Infrastructure for e-manufacturing- Software tools- Hardware- Networking- Implementation

e-Manufacturing fundamentalse-

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e-manufacturing applications

Application (1) - case studies- Web-based bearing design support systems

- Web-based manufacturing assembly simulation

- Web-based intelligent (CBR) selection of cutting tool inserts

- Modelling and simulation of the extended enterprise operations based on dynamic Petri nets

- Remote condition monitoring and control of manufacturing systems

- Creative design search engine

- RFID application for diamond cutting tools’ tooling service

Application (2) - devolved manufacturing

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Web-based Intelligent (CBR) Selection System for Cutting Tool Inserts

A proposed system architecture…

Language selection

Main CBR loop

Standard e-Catalogue search

CBR validation loop

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Modelling and Simulation of the Extended Enterprise Operations Based on Dynamic Petri Nets

EVENTS

ORGANISATION MODELS

PROCESS MODELS

RESOURCES PRODUCTS

DATABASE

INTRANET/ INTERNET

JAVA SIMULATION

REAL-TIME VISUALISATOIN

MANUFACTURING ENTERPRISE

EVENTS

INTERNET

CO-ORDINATOR

DESIGN

MANAGEMENT

INTRANET/ INTERNET

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Internet

Client on the Internet

RT100Robot Arm

Web Camera

Send a live image to the clients

Commands

Response

Remote Condition Monitoring and Control of Manufacturing Systems

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Creative Design Search Engine …

Creative Design & Innovative Manufacturing

- 3D models

- ……

- ……

- ……

- ……

- ……

- ……

- ……

- ……

- ……

- ……

-……

A search engine for innovative/creative …

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RFID Application for Diamond Cutting Tools’ Tooling Service

TaggedCutting Tools

T1…TN

ReaderHost System

with Tool Database

Look up Geometric images SpecificationUser informationRe-sharpening records ……

Update

Read

Identify

Reader

TaggedTools

Host system with Tool Database

Reading Successfully

Antenna

Diamond tools tracking and servicing support sys

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Selected ‘Milestone’ Publications (in e-manufacturing) from the AMEE Group

Books:(1) K. Cheng, D. Webb and R. Marsh, Advances in e-Engineering and Digital Enterprise Technology I (Editors),

Professional Engineering Publishing, London, September 2004.(2) K. Cheng, e-Manufacturing, Fundamentals and Applications, WIT Press, London, February 2005.

Journal Papers:(1) K. Cheng, P.Y. Pan and D.K. Harrison, Internet as a tool with application to agile manufacturing: a web-based

engineering approach and its implementation issues, International Journal of Production Research, Vol.38 No.12, 2000, pp.2743-2759.

(2) K. Cheng, P.Y. Pan and D.K. Harrison, Web-based design and manufacturing support systems: implementation perspectives, International Journal of Computer Integrated Manufacturing, Vol.14 No.1, 2001, pp.14-27.

(3) K. Cheng, M.L. Yang, G.E. Taylor and A. Dow, Petri net as a tool with application in modelling an Internet based virtual manufacturing enterprise, International Journal of Agile Manufacturing, Vol.4 No.2, 2002, pp.100-109.

(4) J. Toussaint and K. Cheng, Implementation of design agility and manufacturing responsiveness on the web: two case studies, Integrated Manufacturing Systems, Vol.13 No.5, 2002, pp.328-339.

(5) R. Bateman and K. Cheng, Devolved manufacturing, Concurrent Engineering: Research and Applications, Vol.10 No.4, December 2002, pp.291-297.

(6) K. Cheng and Y. Popov, Internet enabled modelling of extended manufacturing enterprises using the process based techniques, International Journal of Advanced Manufacturing Technology, Vol.23 No.1, 2004, pp. 148-153.

(7) J. Toussaint and K. Cheng, Web-based CBR (case-based reasoning) as a tool with the application to tooling selection, International Journal of Advanced Manufacturing Technology, Vol. 26, 2006.

(8) R. Bateman and K. Cheng, Extending the product portfolio with ‘devolved manufacturing’: methodology and case studies, International Journal of Production Research, Vol.45, 2006.

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Devolved Manufacturing – (1)

Current developments in e-manufacture are generally ‘factory-centric’

Transport/logistics problems increasing (‘gridlock Europe’)

New technologies are available or emerging

New possibilities … Need to ‘Think outside

the box’…

Internet / WWW

MassCustomisation

RapidManufacture

Key areas for integration

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Agile Manufacturing

Manufacturing Processes Capability

Technology etc.

IT Internet WWW

CAD/CAM etc.

Mass Customisation Mass customisation

Make-to-order Personalisation

etc. …

People/HRM Organisation

Team Working Training

Recruitment Communications

Succession etc.

Organisation Virtual Orgs

Network Orgs Distribution

Logistics Supply chains

Finance etc.

Integrated Approach

Technology

Devolved Manufacturing

Devolved Manufacturing – (2)e-

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Mass Customisation

MASS PRODUCTION

MASS CUSTOMISATION

MASS ‘INDIVIDUALISATION’

Outcome of industrial revolution Driven by production and cost needs

Concept developed in 1980’s

Increases product range by allowing customers to choose from range of options

Needs to be set up with care to avoid extra overheads associated with increased product variety

Ultimate goal of MC ?

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Rapid Manufacturing (RM)

1. The CAD model is sliced into layers

2. RM machine ‘creates’ model

3. Finished Object

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End-user & Practitioner Surveys

Breakdown of Systems by Type

Global RP/RM Installations

Rise in Annual Sales of RP/RM machines (000’s)

Number of Patents Issued for RP/RM Technology

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Case One – CAL system

Typical Race Clutch Construction

Central Splines in Friction Plate Hub

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System Menu

Search Existing Products

Input Spline Dimensions

View 3D Model

Send files for manufacture

Test Mfg at Brunel

Case One – CAL systeme-

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Case Two – wydiwyg.co.uk

Home page

Details

Download mini-CAD program

Use mini-CAD program

View model in 3D

Stage ONE Stage TWO

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Home Page

Register

Find outlet

Outlet details

Upload CAD file

Make payment

Confirmation

Test part

Stage THREE

Case Two – wydiwyg.co.uke-

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Case Three – Creatorium Portal

Customers

Manufacturing outlets

Design companies

The

CREATORIUM web portal

Discussion forums

Designers (individual)

Legislative bodies

RM machine manufacturers

Trade associations

Professional bodies

Academic institutions

Stakeholders in the CREATORIUM Portal

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Customers

Manufacturing outlets

Design companies

The

CREATORIUM web portal

Discussion forums

Designers (individual)

Legislative bodies RM machine

manufacturers

Trade associations

Professional bodies

Academic institutions

Information based stakeholders

Case Study One Case Study Two

CREATORIUM relationship with Cases One and Two

Case Three – Creatorium Portale-

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Discussions

Implementation key issues Start points and direction Organisational issues Technology adoption Strategies for DM Design, legal and ethical issues Control and management of a DM venture

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Acknowledgements

• EPSRC• Royal Society• DTI TCS / Faraday Schemes• NATO Scientific Program• HEFCE• SHEFC

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Thank You!

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